Summary of Contents for ORBITALSERVICE CompactDual - Two in One
- Page 1 Operation Manual CompactDual – Two in One Orbital Welding System CompactDual – Two in One Operation Manual Page 1/53 © 08/2019 Rev 0 / Subject to change without notice!
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Page 2: Table Of Contents
Operation Manual CompactDual – Two in One Table of Contents 1. General Instructions ......................3 2. Safety Instructions ......................4 3. The Power Supply (Front and Rear Panels) ..............5 4. The buttons ........................7 5. The Home Screen ......................8 6. -
Page 3: General Instructions
Operation Manual CompactDual – Two in One 1. General Instructions This Quick Start Guide introduces you to the first steps in how to operate the CompactDual. Manufacturer of the CompactDual: ORBITALSERVICE GmbH Kreuzdelle 13 63872 Heimbuchenthal Germany Tel.: +49-(0)6092 822 94-0... -
Page 4: Safety Instructions
Operation Manual CompactDual – Two in One 2. Safety Instructions Arc welding may harm you and others. For this reason, when working with arc welding, you shall always observe the existing Safety and Accident Prevention guidelines. Warning of dangerous electrical current ... -
Page 5: The Power Supply (Front And Rear Panels)
Operation Manual CompactDual – Two in One 3. The Power Supply (Front and Rear Panels) Display Information „Orbital Welding ON“ Constant current Switching Orbital - Manual Information „Orbital Welding ON“ The switching of hand / orbital is carried out with the right button (orbital - manual). - Page 6 Operation Manual CompactDual – Two in One RS 232 (Bluetooth printer, Main Switch (ON/OFF) Gas connection ¼“ Update box Orbital Software) Connection orbital rotating Remote Control-Foot Switch Power motion (Rotation Weld Head, Supply, Connection Robot, Wire, AVC, OSC) Connection Update Software Power Supply Orbital Remote Control (wired)
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Page 7: The Buttons
Operation Manual CompactDual – Two in One 4. The buttons Start-Button: With this button you can start the welding process and confirm the menus. Stop Button: With this button you can stop the welding process or undo a menu selection. Program Button: With this button we reach the Main Menu. -
Page 8: The Home Screen
Operation Manual CompactDual – Two in One 5. The Home Screen Display sectors and angle degrees Program number 07 (out of 99 High and Base current possible programs) (Info Sector 1) Weld Head 83 (99 possible weld heads) External diameter (42 mm) Wall thickness tube (2.0 mm) Internal Information... -
Page 9: The Main Menu
Operation Manual CompactDual – Two in One 6. The Main Menu The „Programming Key“ and the main menu By pressing the Programming key you reach the main menu. All menu items/signs are easily understandable. They do not need to be translated into different languages. The icon with the thick, black frame is activated by pressing the button and you reach the programming screen. -
Page 10: Creating A New Welding Program
Operation Manual CompactDual – Two in One 7. Creating a new welding program 7.1. The help function (automatic program creation) The control allows operators, even if they are not well versed, to easily reach first welding programs. For this purpose there are basic calculations included in the software, which have been tested for years and that are recommended and practiced by other manufacturers. - Page 11 Operation Manual CompactDual – Two in One Press button Delete program Program library Create new program Assign new program name Page 11/53 © 08/2019 Rev 0 / Subject to change without notice!
- Page 12 Operation Manual CompactDual – Two in One Press button Outside diameter of pipe Press button Page 12/53 © 08/2019 Rev 0 / Subject to change without notice!
- Page 13 Operation Manual CompactDual – Two in One With buttons and the Setting-Enter Button the different data for diameter Wall thickness, Number (model) of the weld head, etc. can now be entered. The procedure is always the same. The number or value with black background can be changed with the arrow keys and then the setting-enter-key.
- Page 14 Operation Manual CompactDual – Two in One Press button Wall thickness of pipe Press button 2 x Page 14/53 © 08/2019 Rev 0 / Subject to change without notice!
- Page 15 Operation Manual CompactDual – Two in One Press button Number (model) of the weld head/welding device Press button Desired number of sectors In this menu item you can specify the number of sectors. The pipe can be divided into up to 6 different segments.
- Page 16 Operation Manual CompactDual – Two in One Press button Desired number of sectors-segments-levels (1-6 possible) Press button Different Symbol for Step-Mode Rotation In these menu items (see hereunder, New 2) you can define the rotation motion (for now continuous motion). Pressing , the motion changes to step mode.
- Page 17 Operation Manual CompactDual – Two in One Press button Press button With buttons you can call up different symbols, numbers, uppercase and lowercase letters, in order to assign a name or a description to the program. This is important in order to find it later in the program library and activate it. Page 17/53 ©...
- Page 18 Operation Manual CompactDual – Two in One Press button If you press the button and the water symbol does not change to a dark background, then we are in presence of a gas cooled weld head. In this case, we have weld head No. 83 (an open weld head OWH 76-Type LB).
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Page 19: Program Library (Database)
Operation Manual CompactDual – Two in One 8. Program library (Database) It is possible to save in the database (library) 99 welding programs with max. 6 sectors each (save). Initial screen: Press menu button Page 19/53 © 08/2019 Rev 0 / Subject to change without notice! - Page 20 Operation Manual CompactDual – Two in One Press button Press button Page 20/53 © 08/2019 Rev 0 / Subject to change without notice!
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Page 21: Deleting Welding Programs (From The Library)
Operation Manual CompactDual – Two in One With the arrow keys you can find and activate the desired program. If the front number is highlighted in black you can jump in tens and you can quickly call a known number, with the back number highlighted, you can scroll through the programs one by one until program After confirming with , the program is activated. - Page 22 Operation Manual CompactDual – Two in One With key to „waste bin“ Confirm with key and choose the program to be deleted with arrow keys Then confirm and the program is deleted. Page 22/53 © 08/2019 Rev 0 / Subject to change without notice!
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Page 23: Change Of Program Name (New Entry)
Operation Manual CompactDual – Two in One 8.2 Change of program name (new entry) Press menu button Press menu button Page 23/53 © 08/2019 Rev 0 / Subject to change without notice! -
Page 24: Saving Power And Wire Parameters (Percentage Changes)
Operation Manual CompactDual – Two in One 8.3 Saving power and wire parameters (percentage changes) Press menu button Page 24/53 © 08/2019 Rev 0 / Subject to change without notice! -
Page 25: The Printing Menu
Operation Manual CompactDual – Two in One Press menu button In this menu item you can save the changed parameters (current and wire speed). The parameters displayed are "reset" to 100% and the values in the program are overwritten. 8.4 The printing menu Press menu button Page 25/53 ©... - Page 26 Operation Manual CompactDual – Two in One Press menu button Press menu button After confirming with button , the current record is printed out. If still no welding has been performed, only the nominal parameters are printed, if already welded, also the welded and measured values and other data, like eventual error or status messages are printed.
- Page 27 Operation Manual CompactDual – Two in One Press button Here you can find a counter (up to 9999). It can be reset using the arrow keys. Press button With this setting (with the Bluetooth printer connected), each weld is automatically printed after welding.
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Page 28: The Main Parameters
Operation Manual CompactDual – Two in One 9. The main parameters Main menu - Initial screen: Press button Main parameters Change parameters (current, times, Program button speeds, angle degrees) Monitored limits Administrator Gas and water test, Test Welding Weld-Setup without arc Page 28/53 ©... - Page 29 Operation Manual CompactDual – Two in One Press button Press button Pre purge time Weld pool building time Down slope time Post purge time Page 29/53 © 08/2019 Rev 0 / Subject to change without notice!
- Page 30 Operation Manual CompactDual – Two in One We would like to show the changes in the following menus, based on the gas pre-flow time. The changes are always executed in the same way. Press button You want to set only 3 seconds (calculated value: 5 sec gas pre-flow time). Page 30/53 ©...
- Page 31 Operation Manual CompactDual – Two in One With button go to the 5 sec display and change the value with the key. Then keep pressing the button , until you see the Diskette at the end of the saving process. Now the changed data are saved.
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Page 32: Other Parameters
Operation Manual CompactDual – Two in One 9.1. Other parameters Keep pressing button . Then you will reach other menus (depending on your Soft and Hardware configuration) Percent wire change during Wire delay Wire retraction Wire stop the welding process Page 32/53 ©... - Page 33 Operation Manual CompactDual – Two in One The wire delay Within the frame parameters, there is the value, Weld Pool Building Time. This is the time in which the welding torch or the tungsten electrode have not yet turned, but only a weld puddle is formed.
- Page 34 Operation Manual CompactDual – Two in One Changing the Wire Stop at 360° Page 34/53 © 08/2019 Rev 0 / Subject to change without notice!
- Page 35 Operation Manual CompactDual – Two in One Wire Activation Press button to reach the field „Wire“. Then press When this field is highlighted in black, the cold wire is activated. The parameters for wire speed are set in the weld programming screen (sectors). Page 35/53 ©...
- Page 36 Operation Manual CompactDual – Two in One Further frame parameters (automatic tacking mode) Dwell time after tacking with purging gas (e.g. for open Number of tack welds (1-99) Current in A Time for tack weld weld heads) Press button to reach the field „Tack“ at the bottom and then press When the field is highlighted in black, the tack mode is enabled.
- Page 37 Operation Manual CompactDual – Two in One Changing all parameters is done exactly in the same way as described several times. Use the arrow keys to move to the field and press the confirmation key to change the data again, using the arrow keys.
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Page 38: Changing The Welding Parameters (Sectors)
Operation Manual CompactDual – Two in One 10. Changing the welding parameters (Sectors) Press button High current Number of sectors (1-6) parameters Units Base current Angle degrees parameters Weld head speed Current Time Wire speed Page 38/53 © 08/2019 Rev 0 / Subject to change without notice! - Page 39 Operation Manual CompactDual – Two in One First of all, we must say that the value highlighted in black is the one that can be changed or viewed. Number of Sectors With the arrow buttons you can scroll through the sectors. You have the possibility to program up to 6 sectors.
- Page 40 Operation Manual CompactDual – Two in One Pressing again, you can change these. As already described above, the changes are always made with the arrow keys and the ENTER button. When all 3 positions are highlighted in black, you can jump to the other parameters, by using the button and perform any changes.
- Page 41 Operation Manual CompactDual – Two in One Possible changes in the base current sector 1 Possible changes in the high current time sector 1 Page 41/53 © 08/2019 Rev 0 / Subject to change without notice!
- Page 42 Operation Manual CompactDual – Two in One Possible changes in the base current time sector 1 High-speed. If continuous rotation is specified in the welding program (frame parameters) then the value High and Base are always the same. You change e. g. the high value and the base value is automatically adopted.
- Page 43 Operation Manual CompactDual – Two in One Wire speed with high current Wire speed with base current In the programming in sector 1, a help function is integrated. Herewith, we try to protect you from any mistakes (that's why sector 1 is so detailed): If you change the speeds (rotation and wire) and the pulse times (in sector 1), all values (except currents) in all other programmed sectors will be overwritten.
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Page 44: Menu Max/Min
Operation Manual CompactDual – Two in One 11. Menu MAX / MIN Press button Monitoring cooling water Monitoring rotation speed Monitoring purging gas Überwachung O2-Start Page 44/53 © 08/2019 Rev 0 / Subject to change without notice! - Page 45 Operation Manual CompactDual – Two in One Monitoring Arc Voltage MIN Monitoring currents Monitoring Arc Voltage MAX At delivery, these values are all set to 0. Registered values are recommendations from our side. Page 45/53 © 08/2019 Rev 0 / Subject to change without notice!
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Page 46: Weld Setup
Operation Manual CompactDual – Two in One 12. Weld Setup Press button Automatic winding and unwinding Sense of rotation Pulsed current Percent change of welding current during the welding process Page 46/53 © 08/2019 Rev 0 / Subject to change without notice! - Page 47 Operation Manual CompactDual – Two in One Automatic winding and unwinding With this function, you have the possibility, e. g. with an open weld head, to wind up the hose assembly before starting of the welding process and after finishing the weld, the weld head returns to the start position.
- Page 48 Operation Manual CompactDual – Two in One Percentage change of the welding parameters This feature is very comfortable. It can be activated during the welding process via the shift key on the remote control. Shift key must light up yellow (LED). Possible adjustments are from 1-10%.
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Page 49: Administrator
Operation Manual CompactDual – Two in One 13. Administrator Press button Contrast Display Set Date - Time Service-Code (only manufacturer) Page 49/53 © 08/2019 Rev 0 / Subject to change without notice! - Page 50 Operation Manual CompactDual – Two in One Set Date and Time Admin 2 For you as a customer, these fields or functions are not accessible. Here are the programming (database) of the weld heads and various information about hardware and software.
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Page 51: Test Menu
Operation Manual CompactDual – Two in One 14. Test Menu Press button Welding without Arc (Test with no current). If highlighted in black Test run Page 51/53 © 08/2019 Rev 0 / Subject to change without notice! - Page 52 Operation Manual CompactDual – Two in One Gas test: If this field is highlighted in black, the solenoid valve is activated and a gas test with flow control is performed. Water test: If this field is highlighted in black, the solenoid valve is activated and a water test with flow control is performed.
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Page 53: Customer Service
15. Customer Service For ordering spare parts, there is a separate spare parts list. Small defects have to be repaired only from trained staff, after briefing from Orbitalservice GmbH. Major damage on weld heads must be repaired in our company.